Baby Steps

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Baby Steps Learning to Balance

• How much did I make?
• Where did it go?
• Does it agree with SAP?

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ATOFINA Chemicals, Inc.Calvert City, Kentucky
Plant

• Products
• Refrigerants
• HFC Forane F-134a
• HCFCs Forane F-141b, F-142b
• Kynar PVDF high performance plastic
• HCl
• Batch Continuous Processes
• PI Since 9/97

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ATOFINA Worldwide

• Chemicals branch of TotalFinaElf
• 72,000 employees
• Worlds 5th largest chemical company
• Petrochemicals Commodity Polymers
• Intermediates Performance Polymers
• Specialty Chemicals

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In the Beginning

• Poor yield calculation accuracy
• Difficult to determine source of loss
• Raw material and finished product transfers
  measured by level change
• Few level/temperature transmitters for finished
  product storage
• Manual data entry from log sheets to
  production/inventory spreadsheet

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Where is the problem?Whos responsible?

• In the production unit?
• Non-optimum process operation
• Leaks
• In logistics?
• Loading accuracy
• Leaks
• Historically the production unit held responsible
  for all yield problems
• First step in improvement is knowing where the
  problem is located

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HCFC Units
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Instrumentation Added

• Mass Flowmeters to measure transfers
• PI-Totalizers for daily/monthly totals
• Level transmitters and RTDs added
• Accurate strapping tables developed
• Many horizontal tanks with various heads
• Liquid and vapor density calculations developed
  to provide tank mass
• Calculations implemented in PI-ACE MDB
• New production/inventory spreadsheet with PI
  providing majority of input automatically

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Product Properties
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Vessel Properties
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Vessel Aliases
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PI-ACE Manager
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Inventory Input
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Inventory Report
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Real Time Inventory
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Transfer and Inventory
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PI/SAP/GPMate Integration

• Goal is to build bridges between the islands
• Automated daily reports
• Production
• Yield
• Variance
• Energy
• Inventory
• Compare PI values to SAP data

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Flow
Run Unattended Late PM
Run Unattended Early AM
Ready for Users upon Arrival
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PI/SAP Integrated Report
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Improvements

• Integrated into daily production reports
• Reduced manual entries by 90
• Fewer SAP surprises
• Finding where losses occur sooner saves

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Is It Finished? Is It Useful?

• NO!
• Problems to resolve
• Refine level measurement
• SAP timing issues
• Still learning about the mysteries of SAP
• Enhance reporting of KPIs
• Yes!

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If you get down because you feel like Youre
going in circles
One step forward.
Two steps back
Dont get upset
A little Advice From Otis
Be thankful for the circle, youll still get
there Depending on where you start it might take
Twice as long or even much shorter than moving
Constantly in the same direction.
Just remember to look over your shoulder so You
dont pass up the solution when approaching It
from the direction you dont expect!